Capacity Validation Study – TCF
Material Movement Study – Blanking & Stamping
February 3, 2023
Cylinder Block Machining Line – Throughput Improvement
February 3, 2023
Automotive TCFCapacity Validation Study
Validating the TCF line to produce target throughput
Key Points
- Multimodel Assembly line
- Subassembly line breakdown effect on
mainline - Throughput improvement roadmap
- All types of carriers/hangers (10 types) optimized; outcome used for purchasing
decision
Client's Challenge
- Effect of introduction of new models
- Amount of blockage in the system due to downtimes
- Optimum number of carriers
- Buffer/ Decoupler capacity
PMI's Approach
- Analysis of Data, building the model, and verification
- Analysis of baseline model results
- Buffer Sensitivity Analysis for some parts of the Chassis
- Carrier optimization for every subassembly
- What-Ifs to reach standard uptime
Findings & Recommendation
- Model was found to fall short of achieving the target
- Number of extra fuel fill equipment determined to reach
desired uptime at Flattop - De-couplers before and after Chassis line 6 were identified as the
bottleneck - What-ifs conducted to find options to meet targets
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